CN113792737B - Method for testing stay time of materials in cement mill based on image recognition technology - Google Patents
Method for testing stay time of materials in cement mill based on image recognition technology Download PDFInfo
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- CN113792737B CN113792737B CN202011529030.3A CN202011529030A CN113792737B CN 113792737 B CN113792737 B CN 113792737B CN 202011529030 A CN202011529030 A CN 202011529030A CN 113792737 B CN113792737 B CN 113792737B
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- 239000004568 cement Substances 0.000 title claims abstract description 68
- 239000000463 material Substances 0.000 title claims abstract description 63
- 238000000034 method Methods 0.000 title claims abstract description 49
- 238000012360 testing method Methods 0.000 title claims abstract description 46
- 238000005516 engineering process Methods 0.000 title claims abstract description 10
- GNBHRKFJIUUOQI-UHFFFAOYSA-N fluorescein Chemical compound O1C(=O)C2=CC=CC=C2C21C1=CC=C(O)C=C1OC1=CC(O)=CC=C21 GNBHRKFJIUUOQI-UHFFFAOYSA-N 0.000 claims abstract description 76
- 238000000227 grinding Methods 0.000 claims abstract description 43
- 239000000843 powder Substances 0.000 claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 claims abstract description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 238000009826 distribution Methods 0.000 claims description 8
- 239000011521 glass Substances 0.000 claims description 7
- 238000004898 kneading Methods 0.000 claims description 6
- 238000005070 sampling Methods 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 4
- 238000010998 test method Methods 0.000 claims description 4
- 238000011049 filling Methods 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 238000005303 weighing Methods 0.000 claims description 3
- 241000227425 Pieris rapae crucivora Species 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 5
- 238000011179 visual inspection Methods 0.000 abstract description 3
- 238000002360 preparation method Methods 0.000 abstract description 2
- 238000011002 quantification Methods 0.000 abstract description 2
- 238000009423 ventilation Methods 0.000 abstract description 2
- 229910052602 gypsum Inorganic materials 0.000 description 11
- 239000010440 gypsum Substances 0.000 description 11
- 230000014759 maintenance of location Effects 0.000 description 11
- 238000004364 calculation method Methods 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- AKEJUJNQAAGONA-UHFFFAOYSA-N sulfur trioxide Chemical compound O=S(=O)=O AKEJUJNQAAGONA-UHFFFAOYSA-N 0.000 description 2
- 230000004913 activation Effects 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000700 radioactive tracer Substances 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B7/00—Hydraulic cements
- C04B7/36—Manufacture of hydraulic cements in general
- C04B7/48—Clinker treatment
- C04B7/52—Grinding ; After-treatment of ground cement
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Analysing Materials By The Use Of Radiation (AREA)
- Sampling And Sample Adjustment (AREA)
Abstract
The invention discloses a method for testing the stay time of materials in a cement mill based on an image recognition technology, which belongs to the technical field of cement production and comprises four procedures of sample preparation of a fluorescein cake, feeding and taking of fluorescein, acquisition of a fluorescein image and identification and quantification of the fluorescein image, and can realize rapid and accurate stay time test of the materials in the cement mill. The plastic cake is prepared by adding water into the fluorescein powder and the grinding material, so that the effect that the fluorescein powder is blown to the grinding tail quickly after ventilation in the grinding is prevented, the test result is influenced, the fluorescein identification adopts an image identification method, the shooting task can be finished only by using a low-cost portable handheld microscope, each sample shooting only needs 3-4 minutes, and all sample shooting is finished only for 1 hour; the computer image recognition technology is used, quantitative statistics of fluorescein can be rapidly realized, subjective judgment of manual visual inspection is avoided, and the test result is more accurate and reliable.
Description
Technical Field
The invention relates to the technical field of cement production, in particular to a method for testing the stay time of materials in a cement mill based on an image recognition technology.
Background
The annual output of cement in China exceeds 24 hundred million tons, and cement becomes one of the most important basic building materials for national economic construction. The ball mill is applied to the cement industry for hundreds of years, is always the main host equipment for the grinding operation of cement enterprises, and contains the ball mill in most of the grinding production processes of the cement enterprises in China. The retention time of materials in the ball mill is one of important reference indexes for judging the running state and grinding efficiency of the cement ball mill, and directly influences the fineness and temperature of the ground cement and the quality of the final cement product, so that the accurate grasp of the retention time of the materials in the cement ball mill is particularly important, and is one of skills which must be grasped by cement grinding process technical staff.
The existing method for testing the retention time of materials in a cement ball mill mainly comprises the following steps:
① Gypsum method: gypsum (natural gypsum or industrial by-product gypsum) is one of the retarder components which must be added in cement production, and the main components are sulfur trioxide and calcium oxide. In actual production, the SO 3 content of the grinding stone paste can be measured by adjusting the mixing amount of the grinding stone paste (generally increasing the mixing amount of the gypsum by 3% -5% or stopping gypsum feeding), and sampling on a grinding chute, wherein the time from the beginning of sampling to the time when the SO 3 content in a sample reaches a peak value or a minimum value is the stay time of materials in the grinding.
② Fluorescein method: the fluorescein is used as a tracer medium, can be dissolved and diluted in water, and is bright yellow-green under the intensity of ultraviolet light. The testing process is to put fluorescein into a mill according to a certain proportion, sample at the mill tail at regular time, generally measure about 15-20 min, dissolve the cement sample in a transparent glass container, put the glass container under the ultraviolet light of a darkroom, judge the time corresponding to the maximum brightness intensity sample as the stay time of the material in the mill by visual inspection, or test the relative content of fluorescein by using a fluorescence photometer, draw a stay time distribution diagram according to the sampling time and the relative content of fluorescein, and the peak value in the distribution diagram corresponds to the stay time of the material in the mill.
③ Theoretical calculation method: the calculation formula of the retention time of the materials in the mill is as follows: t=60 g/a, where t is the in-mill material residence time; g is the material storage amount in the grinding bin; a is the throughput of the mill. The accurate numerical value of the stock quantity in the grinding bin is difficult, the arc-shaped section area test with the chord of the material surface in the grinding bin is required to be stopped, the material volume test is performed, the calculation is performed, the circulation load test is required to be performed on the powder selecting machine for the material throughput A in the grinding bin, and the whole test method is complex.
The above-mentioned cement ball mill internal grinding material flow rate testing methods have limitations respectively:
Gypsum method: the central control personnel need to adjust production ingredients, need to adjust the gypsum doping amount, easily cause other negative effects, such as influencing the cement product quality, the content of grinding SO 3 is unqualified, and the performance assessment of operators is influenced. Particularly in the circular flow mill, the material to be milled is selected from coarse powder by a powder selecting machine and returned to the mill, the gypsum feeding is stopped for 20-30 min, the gypsum in the mill still cannot be emptied or the gypsum feeding quantity is increased, and the peak value of the SO 3 of the material to be milled is not obvious.
Theoretical calculation method: the accurate numerical value of the material quantity stored in the grinding bin is difficult, the grinding is required to be stopped for testing, the production is influenced during the calibration, and the testing process requires the calibration personnel to enter the grinding for testing, so that the safety risk is high.
Fluorescein method: the traditional fluorescein judges the strength of the fluorescent agent by using an artificial visual method, so that the judgment result is high in subjectivity and difficult to obtain a quantitative index; the relative content of the fluorescein is difficult to test by using a fluorometer, because the content of the fluorescein in a cement grinding mill is trace (the yield of the cement grinding mill is usually 150-250 t/h, and the content of the fluorescein for testing is only hundreds of grams), the accuracy of a test result is low, and the content of the fluorescein can not be detected sometimes. Secondly, most cement enterprises at present are not provided with a fluorescence photometer (high price) for specially testing fluorescein, and the system calibration cannot be finished on site of a production base.
Disclosure of Invention
Aiming at the limitations of the existing method for testing the stay time of materials in the cement ball mill, the invention provides the method for testing the stay time of the materials in the cement ball mill based on the image automatic identification technology, which mainly aims at solving the problems of inaccurate test, inconvenient operation, incapability of completing the test in a production field and the like in the quantitative process of the content of the fluorescein in the existing method for testing the fluorescein, and simultaneously optimizes the working procedure of the whole method for testing the fluorescein, so that the testing result is more convenient and accurate.
The invention optimizes the whole flow of the material stay time in the cement mill by a fluorescein method, and the testing method comprises four procedures of fluorescein cake sample preparation, fluorescein feeding and taking, fluorescein image acquisition and fluorescein image identification and quantification, so that the quick and accurate test of the material stay time in the cement mill can be realized.
A method for testing the stay time of materials in a cement mill based on an image recognition technology comprises the following steps:
Step 1: preparing a sample of the fluorescein cake, adding yellow fluorescein powder into a ground powder material, fully and uniformly mixing the ground powder material in a barrel, and adding water to knead the mixture to form a plastic cake;
Step 2: feeding a fluorescein cake and grinding the tail to obtain materials, putting the plastic cake on a long-handle flat shovel, feeding the plastic cake into a grinding mouth of a cement ball grinder, starting timing, taking materials on a grinding chute at intervals of fixed time, and filling the materials into a paper sample bag;
step 3: obtaining a fluorescein image, namely placing the obtained cement sample containing the fluorescein into a die, flattening the cement sample by using a glass sheet, and taking a picture by using a hand-held portable microscope to obtain a sample picture;
Step 4: and quantitatively identifying the fluorescein image, transmitting the photographed image to a computer, identifying the foreground by using the Ojin threshold segmentation, separating out the fluorescein powder spots by using a pattern searching method, counting the number of the fluorescein spots, and drawing a stay time distribution map according to the number of the fluorescein spots per minute, wherein the peak value in the distribution map corresponds to the stay time of the material in the mill.
Further, the specific process of the step 1 is as follows: 1-1.5 g of fluorescein powder is used for each 1t/h of production of open-circuit cement, 2-3 g of fluorescein powder is used for each 1t/h of closed-circuit cement, the fluorescein powder and 3-5 kg of ground materials are fully and uniformly mixed in a 10L small barrel, water is added into the barrel for 4-5 times, 200-300 g of water is added each time, and a plastic cake is formed by continuously kneading according to a dough kneading method.
Further, the specific process of the step 2 is as follows: 1 kg of materials are taken on the grinding chute every 1 minute, and are filled into paper sample bags, and the total time is 15 minutes, and the sampling is finished.
Further, the specific process of the step 3 is as follows: taking 200-300 g of a cement sample containing fluorescein per minute, placing the cement sample into a custom-made square mold with the length of 150-20 mm, flattening the cement sample by using a glass sheet, taking the cement sample into a room without solar interference, taking a picture by using a hand-held portable microscope, and using a fluorescent light source bulb to replace a common white light source by using a microscope light source.
Further, the specific photographing process comprises the following steps: in the photographing process, in order to keep the lens unchanged, the mold is moved by hands, one piece of the mold is photographed and immediately moved to the next area, so that all areas of the whole mold are photographed, the representativeness of samples is ensured, and the same number of photos are photographed for each sample.
Further, the number of pictures taken per sample is 40-60, and the magnification of the photographing is 100-200 times.
Further, the specific process of step 4 is as follows: and carrying out batch identification on 40-60 samples per minute by using image software, and calculating the number of the fluorescein spots to obtain the content of the fluorescein powder.
The invention adopts the technical proposal and has the following technical effects:
According to the invention, the plastic cake is prepared by adding water into the fluorescein powder and the grinding material, so that the effect of the fluorescein powder on the test result is prevented from being influenced by the rapid blowing of the fluorescein powder to the grinding tail along with ventilation in the grinding, the shooting task can be completed by using a low-cost portable handheld microscope only, each sample shooting only needs 3-4 minutes, and all samples are shot for only 1 hour; the computer image recognition technology is used, quantitative statistics of fluorescein can be rapidly realized, subjective judgment of manual visual inspection is avoided, and the test result is more accurate and reliable.
Drawings
FIG. 1 is a plot of the spots of fluorescein according to the present invention.
FIG. 2 is a graph of the fluorescein profile of the residence time of the material in the mill according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to preferred embodiments for the purpose of making the objects, technical solutions and advantages of the present invention more apparent. It should be noted, however, that many of the details set forth in the description are merely provided to provide a thorough understanding of one or more aspects of the invention, and that these aspects of the invention may be practiced without these specific details.
The method for testing the stay time of the materials in the cement mill based on the image recognition technology comprises the following specific steps:
In this example, a cement grinding production line is taken as an example, and the production line is a combined closed circuit grinding system consisting of a CLF170-100 roller press and a phi 4.2-13.5 m two-bin ball mill, and the system can shut down a powder selecting machine to carry out open circuit process production. Wherein the production rate of the cement of the P.O42.5 variety produced by the open circuit process is 170-180 t/h, and the production rate of the cement of the M32.5 variety produced by the closed circuit process is 210-220 t/h. The company has higher power consumption of cement grinding and frequent coarse running of the fineness of the cement products to be ground, so that the residence time of materials in the cement grinding needs to be mastered to judge whether the structure in the grinding needs to be optimized.
The method is adopted by the calibration personnel to test the retention time of materials in the cement mill on the production line, and the specific test method is as follows:
1. preparing a fluorescein cake sample: weighing and weighing the fluorescein powder in a laboratory,
250 G of fluorescein powder is weighed by P.O42.5 cement variety test, 450g of fluorescein powder is weighed by M32.5 cement variety test, and the mixture is filled into a sample bag for standby. Taking 5 kg of sample from a grinding chute, putting the sample into a barrel, pouring fluorescein, fully stirring for 5 minutes to be uniform by using a sample spoon, adding water into the barrel for 5 times, adding 200g of water each time, and kneading continuously according to a dough kneading method while adding water to form a plastic cake.
2. Feeding and tailing grinding of a fluorescein cake, and taking materials: a calibrator put the plastic cake on the long handle flat spade, push the mill mouth into the mill entrance, follow the mill material into the mill together, use the stopwatch to start timing. And the other calibration personnel takes a sample on the grinding chute at intervals of 1min by using a sampler, and fills the sample into a paper sample bag, and the sample is ended after 15 min. The calibration personnel respectively test two varieties of P.O42.5 cement and M32.5 cement. (the test is performed after 2 hours of balanced operation after the production is transferred).
3. Fluorescein image acquisition: all samples of the fluorescein sampled in the field were taken back to the laboratory and 200g of samples per minute were placed into custom 150 x 20mm molds and flattened using glass flakes. The mold filled with the sample and the hand-held portable microscope equipped with the fluorescent light source are brought into the room, all the light sources and curtains are turned off, and the room is dimmed as much as possible. The mold was placed on a microscope stage, the focal length was adjusted and magnification was set to 100 times, and continuous photographing was started. In the photographing process, the die is moved by hand to photograph one area immediately to the next area for photographing in order to keep the position of the lens unchanged, so that all areas of the whole die are photographed, the representativeness of samples is guaranteed, and 50 photos are photographed for each sample.
4. And (3) quantitatively identifying a fluorescein image: taking the shot image out of the memory card of the microscope, importing the shot image into a personal computer, segmenting and identifying the foreground by using an Ojin threshold in image identification software, separating out the spots of the fluorescein powder (figure 1) by using a pattern searching method, and counting the number of the spots of the fluorescein. The number of luciferins was calculated by batch identification of 50 samples per minute using image software. The residence time distribution graph is drawn according to the number of fluorescein spots per minute, the peak value in the distribution graph corresponds to the residence time of the materials in the mill, and the test result is shown in figure 2.
The quick measurement test result shows that the retention time of the material in the P.O42.5 cement mill produced by the production line is 8 minutes, the retention time of the material in the M32.5 cement mill produced by the production line is 6 minutes, and the test result shows that the flow rate of the material in the mill is too high. Therefore, the company immediately makes measures for slowing down the flow rate of materials in the mill, optimizes the structure in the mill (increases the heights of the activation ring and the stop ring, and the like), and optimizes the operation of the cement mill
Parameters (reducing the air quantity of the mill blower). After the system is optimized and stably operated for 1 month, the calibration personnel tests the retention time of the materials in the mill, and the test result is that the retention time of the materials in the cement mill is 11min by P.O42.5, and the retention time of the materials in the cement mill is 9min by M32.5.
Through effectively slowing down the stay time of materials in the mill, the fineness of the cement to be ground is effectively controlled, the coarse phenomenon does not occur any more, meanwhile, the power consumption of the P.O42.5 cement grinding process is reduced by 1 kW.h/t, and the power consumption of the M32.5 cement grinding process is reduced by 1.5 kW.h/t.
The test method provided by the invention can be used for rapidly and effectively measuring the retention time of materials in the ball mill, and the test result can guide process operators to optimize the production process flow so as to achieve the effects of ensuring the quality of cement products and saving energy and reducing consumption.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (1)
1. A method for testing the stay time of materials in a cement mill based on an image recognition technology is characterized by comprising the following steps of: the test method comprises the following steps:
Step 1: preparing a sample of the fluorescein cake, adding yellow fluorescein powder into a ground powder material, fully and uniformly mixing the ground powder material in a barrel, and adding water to knead the mixture to form a plastic cake;
Step 2: feeding a fluorescein cake and grinding the tail to obtain materials, putting the plastic cake on a long-handle flat shovel, feeding the plastic cake into a grinding mouth of a cement ball grinder, starting timing, taking materials on a grinding chute at intervals of fixed time, and filling the materials into a paper sample bag;
step 3: obtaining a fluorescein image, namely placing the obtained cement sample containing the fluorescein into a die, flattening the cement sample by using a glass sheet, and taking a picture by using a hand-held portable microscope to obtain a sample picture;
Step 4: quantitatively identifying a fluorescein image, transmitting the photographed image to a computer, identifying a prospect by using the division of an Ojin threshold value, separating out fluorescein powder spots by using a pattern searching method, counting the number of the fluorescein spots, and drawing a stay time distribution map according to the number of the fluorescein spots per minute, wherein a peak value in the distribution map corresponds to the stay time of materials in a mill;
The specific process of the step 1 is as follows: 1-1.5 g of fluorescein powder is used for each 1t/h of production of open-circuit cement, 2-3 g of fluorescein powder is used for each 1t/h of closed-circuit cement, the fluorescein powder and 3-5 kg of ground materials are fully and uniformly mixed in a 10L small barrel, water is added into the barrel for 4-5 times, 200-300 g of water is added each time, and a plastic cake is formed by continuously kneading according to a dough kneading method;
the specific process of the step 2 is as follows: taking 1 kg of materials on the grinding chute every 1 minute, filling the materials into a paper sample bag, taking the materials for 15 minutes in total, and ending sampling;
the specific process of the step 3 is as follows: weighing 200-300 g of a cement sample containing fluorescein per minute, placing the cement sample into a customized square mold with the length of 150-20 mm, flattening the square mold by using a glass sheet, taking the sample into a room without solar interference, photographing by using a hand-held portable microscope, and using a fluorescent light source bulb to replace a common white light source by using a microscope light source;
The specific process of photographing is as follows: the photographing process is to keep the lens unchanged, move the die by hand, photograph one piece and immediately move to the next area, ensure that all areas of the whole die are photographed, ensure the sample representativeness, and photograph the same number of photos of each sample;
the number of the pictures shot by each sample is 40-60, and the shooting magnification is 100-200 times;
The specific process of the step 4 is as follows: and carrying out batch identification on 40-60 samples per minute by using image software, and calculating the number of the fluorescein spots to obtain the content of the fluorescein powder.
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| CN103902967A (en) * | 2012-12-27 | 2014-07-02 | 杭州美盛红外光电技术有限公司 | Image identification control device and image identification control method |
| CN108254294A (en) * | 2018-03-26 | 2018-07-06 | 杭州培聚教育科技有限公司 | The visualization of cement-based material crack water absorption course and water absorption rate measuring device and method |
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| CN101788480A (en) * | 2010-01-29 | 2010-07-28 | 浙江大学 | Hepatoxic substance sieving and evaluating method based on fluorescence labeling |
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| CN108254294A (en) * | 2018-03-26 | 2018-07-06 | 杭州培聚教育科技有限公司 | The visualization of cement-based material crack water absorption course and water absorption rate measuring device and method |
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